Pump system and method having a quick change motor drive

Abstract

A precision pump system having a motor driver for accurately and repeatedly delivering process fluid, (e.g., photo chemicals) using a pumping fluid with minimal process fluid loss to a fabrication process and whereby the motor driver can be easily and quickly replaced without interrupting the fluid flow path. This is accomplished with the use of a process fluid reservoir and a pumping fluid reservoir that are associated with the pump, either integrated with the pump or closely adjacent. In addition, this precision pump system can be remotely monitored, viewed and controlled over the Internet. In addition, trapped process fluid within a downstream filtering block can be recirculated to the process fluid reservoir when trapped gas in the filter is removed. Furthermore, a nitrogen gas source is connected to the process fluid reservoir via a valve in case a need to insert a gas is required.

What is claimed is: 
     
       1. A pump that permits the replacement of an associated motor drive system, said pump comprising:
 a driving means disposed within a pump housing for driving a fluid in said pump; 
 a motor drive system coupled to said driving means for activating said driving means; 
 said motor drive system being releasably secured to said pump housing such that said motor drive system and said driving means coupled to said motor drive system can be quickly disconnected from said pump housing, removed as a single assembly and replaced with another motor drive system and another driving means coupled thereto; 
 a pumping chamber for dispensing a process fluid, said pumping chamber comprising a diaphragm that separates said pumping chamber into first and second chambers, said first chamber being in fluid communication with said driving means through a first valve and comprising a pumping fluid, said second chamber comprising the process fluid therein received from a process fluid flow path; 
 a pumping fluid reservoir for storing said pumping fluid therein, said pumping fluid reservoir being in fluid communication with said driving means through a second valve, and wherein said motor drive system is replaced when said first and second valves are alternately activated, said pump remaining on line by avoiding any interruption in said process fluid flow path during said motor drive system replacement; 
 a process fluid reservoir coupled to said second chamber through a third valve to form said process fluid flow path; 
 a fourth valve located between a second chamber outlet and a filter; and 
 a pump controller, said pump controller controlling said first, second, third and fourth valves automatically. 
 
     
     
       2. The pump of  claim 1  wherein said motor drive system is coupled to a top portion of said pump housing. 
     
     
       3. The pump of  claim 1  wherein said pumping fluid reservoir is integrated within pump housing. 
     
     
       4. The pump of  claim 1  wherein said pumping fluid reservoir comprises an inlet coupled to said driving means and wherein said inlet is located on a bottom side of said pumping fluid reservoir, said bottom side located inlet preventing air from being transferred to the driving means during replacement of said motor drive system when air is fed into said pumping fluid reservoir to increase the level of pumping fluid in said driving means. 
     
     
       5. The pump of  claim 1  wherein said process fluid reservoir is upstream of said driving means and wherein a filter is positioned downstream of said driving means. 
     
     
       6. A pump that permits the replacement of an associated motor drive system, said pump comprising:
 a driving means disposed within a pump housing for driving a fluid in said pump; 
 a motor drive system coupled to said driving means for activating said driving means; 
 said motor drive system being releasably secured to said pump housing such that said motor drive system and said driving means coupled to said motor drive system can be disconnected from said pump housing, removed as a single assembly and replaced with another motor drive system and another driving means coupled thereto; 
 wherein said driving means comprises a piston and cylinder arrangement and wherein said motor drive system is threadedly coupled to said piston; 
 wherein said motor drive system is coupled to a top portion of said pump housing; 
 wherein said piston comprises a means for displacing gas upward away from pumping fluid in said cylinder when a replacement motor drive system is installed; and 
 wherein said means for displacing gas upward comprises a coned tip. 
 
     
     
       7. The pump of  claim 6  wherein said motor drive system can be disconnected from said pump housing along with said piston. 
     
     
       8. The pump of  claim 7  wherein said motor drive system can be decoupled from said piston before said motor drive system is disconnected. 
     
     
       9. The pump of  claim 6  further comprising a pumping chamber for dispensing a process fluid, said pumping chamber comprising a diaphragm that separates said pumping chamber into first and second chambers, said first chamber being in fluid communication with said cylinder through a first valve and comprising a pumping fluid, said second chamber comprising the process fluid therein received from a process fluid flow path. 
     
     
       10. The pump of  claim 9  further comprising a pumping fluid reservoir for storing said pumping fluid therein, said reservoir being in fluid communication with said cylinder through a second valve, and wherein said motor drive system is replaced when said first and second valves are alternately activated, said pump remaining on line by avoiding any interruption in said process fluid flow path during said motor drive system replacement. 
     
     
       11. The pump of  claim 10  wherein said reservoir is integrated within said pump housing. 
     
     
       12. The pump of  claim 10  further comprising a process fluid reservoir coupled to said second chamber through a third valve to form said process fluid flow path. 
     
     
       13. The pump of  claim 12  further comprising a fourth valve located between a second chamber outlet and a filter. 
     
     
       14. The pump of  claim 13  further comprising a pump controller, said pump controller controlling said first, second, third and fourth valves automatically. 
     
     
       15. The pump of  claim 12  wherein said process fluid reservoir is upstream of said piston and cylinder arrangement and wherein a filter is positioned downstream of said piston and cylinder arrangement. 
     
     
       16. The pump of  claim 6  further comprising a pumping fluid reservoir comprising an inlet coupled to said cylinder and wherein said inlet is located on a bottom side of said pumping fluid reservoir, said bottom side located inlet preventing air from being transferred to the cylinder during replacement of said motor drive system when air is fed into said pumping fluid reservoir to increase the level of pumping fluid in said cylinder. 
     
     
       17. A method of replacing an associated motor drive system for a pump, said method comprising:
 (a) disposing a driving means comprising a piston and cylinder arrangement within a pump housing for driving a fluid in said pump; 
 (b) coupling a motor drive system to said driving means for activating said driving means; and 
 (c) releasably securing said motor drive system and said driving means to said pump housing such that said motor drive system and said driving means can be quickly disconnected from said pump housing, and removed as a single assembly; 
 (d) replacing said motor drive system and said driving means with another motor drive system and another driving means coupled thereto; 
 (e) providing a pumping chamber that dispenses a process fluid and wherein said pumping chamber comprises a diaphragm that separates said pumping chamber into first and second chambers and wherein said first chamber is in fluid communication with said cylinder through a first valve for receiving said process fluid therein and wherein said second chamber receives said process fluid therein from a process fluid flow path; 
 (f) providing a reservoir for storing said pumping fluid therein, said reservoir being in fluid communication with said cylinder through a second valve for transferring said pumping fluid between said cylinder and said reservoir; and 
 (g) alternately activating said first and second valves to replace said motor drive system while said pump remains on line by avoiding any interruption in said process fluid flow path during said motor drive system replacement; 
 wherein said step of replacing said motor drive system comprises disengaging said piston along with said motor drive system; 
 wherein said fluid is a substantially incompressible pumping fluid; 
 wherein said step of disposing a driving means comprising a piston and cylinder arrangement comprises integrating said reservoir within a pump body, said pump body comprising said piston and cylinder arrangement; 
 wherein said step of disposing a driving means comprising a piston and cylinder arrangement further comprises forming means, at a distal end of said piston, for displacing air upward away from said pumping fluid in said cylinder when a replacement motor drive system in installed; and 
 wherein said step of forming means for displacing air comprises forming a coned tip at said distal end of said piston. 
 
     
     
       18. The method of  claim 17  wherein said step of releasably securing said motor drive system comprises coupling said motor drive system to a top portion of said pump housing. 
     
     
       19. The method of  claim 17  further comprising the step of coupling a process fluid reservoir to said second chamber through a third valve to form said process fluid flow path. 
     
     
       20. The method of  claim 19  further comprising the step of coupling a fourth valve between a second chamber outlet and a filter. 
     
     
       21. The method of  claim 20  further comprising the step of controlling said first, second, third and fourth valves automatically. 
     
     
       22. The method of  claim 19  further comprising the step of positioning said process fluid reservoir upstream of said piston and cylinder arrangement and positioning a filter downstream of said piston and cylinder arrangement.